Cheese mold apparatus

ABSTRACT

A rectangular cheese hoop is constructed to conform generally in outside dimensions, assembly and operation to a conventional block cheese hoop. If desired, a block cheese hoop may be modified by the insertion of novel adapters. The adapters (or equivalent horn hoop structures) are in the form of platen members, each of which carries at least one, preferably two, concave molds shaped as longitudinal sections of a cylinder. The horn cheese hoop is loaded with curd and pressed in the fashion conventional with block cheese hoops. Thus, pressing is in a direction normal the axis of the fully pressed horn.

C United States Patent [151 3 Fowler 1 Oct. 24, 1972 [54] CHEESE MOLDAPPARATUS 3,095,647 7/1963 Rossen ..31/44 [72] Inventor.. Dean A.Fowler, Smnthfield, Utah a y Examiner Hugh R. Chamblee Assigneei ValleyDairy Association, Attorney-David V. Trask, C. Harvey Gold and Wil-Smithfield, Utah s Britt [22] Filed. June 1, 1970 [57] ABS RAC [2]]App]. No.: 42,343

, A rectangular cheese hoop is constructed to conform generally inoutside dimensions, assembly and opera- [52] U.S. Cl. ..425/195, 425/89,45 15/356 tion to a conventional block cheese hoop If desired, a [51]Pt. CL... ..Aolj 25/15 block Cheese hoop may b modfified by theinsertion [58] Field of Search ..31/44, 46, 89; 249/ l 12, 113 of noveladapters The adapters (or equivalent hom hoop structures) are in thefonn of platen members, [56] References C'ted each of which carries atleast one, preferably two, UNITED STATES PATENTS concave molds shaped aslongitudinal sections of a cylinder. The horn cheese hoop lS loaded-withcurd 2,266,336 12/1941 Royer ..31/46 and pressed in the fashionconventional with block 3,199,195 8/1965 DeBoer ..3l/44 cheese hoops.Thus pressing is in a direction normal Thompson ..3 X th i f the pressedhom 2,193,0l3 3/1940 Weinberg ..31/44 X 3,514,857 6/1970 Rossen ..31/447 4 Claims, 10 Drawing Figures sum 1 0F 5 PATENTED00124 1912 INVENTOR.Dean A. Fowler BY V His Attorney PATENTED OCT 24 I972 SHEET 2 [1F 3 3INVENTOR. Dean A. Fowler HIS ATTORNEY PATENTED 4 3.700.373

SHEU 3 [IF 3 4 INVENTOR. 8 Dean A. Fowler (QM/W JF/GJO ms AH orney 1CHEESE MOLD APPARATUS BACKGROUND OF THE INVENTION Field This inventionrelates to the production of horns of cheese and provides both novelmethods and apparatus therefor.

State of the Art Horn cheeses have long enjoyed a preference over blockcheeses in the marketplace. This preference is reflected in the higherper pound price that consumers are willing to pay for horn cheesescompared to directly competitive block cheeses. For example, longhorncheddar cheese has traditionally sold for a higher price than blockcheddar cheese.

The classical method for preparing longhorn cheese involves thepreparation of curd according to the same procedure generally used forthe preparation of American varieties of cheese, notably cheddar,Monterrey and Colby cheeses. The curd. is then loaded into individualhorn hoops which are linedwith cheesecloth. Classical horn hoops areapproximately cylindrical, but they are beveled slightly to facilitatethe removal of pressed cheeses and to permit nesting of the hoops duringthe pressing procedure. Typically, a circular hoop is about 15 inches inlength and tapers from a maximum diameter at its mouth or open end ofabout 6 1% inches to a minimum diameter at its bottom or closed end ofabout k inches. Special cheesecloth liners (press cloths) must beprovided for use in this shape of hoop.

After the horn hoops are filled with curd to the appropriate height, thecheesecloth is folded over the top of the curd, and the bottom of onehoop is nested into the mouth of another hoop. A series of hoops nestedin this fashion is placed in a press, and pressure is applied to theseries by forcing the hoop at one end of the series toward the hoop atthe opposite end of the series. This method produces individual horncheeses of approximately cylindrical shape. The horns are removed fromthe hoops, unwrapped from the cheesecloth, rewrapped in suitablewrapping material, such as paper, vinyl, or other types of plastic, andare stood on end within a cylindrical sleeve, e.g., of cardboard, foraging. During the aging process, the cheese acquires a substantiallycylindrical configuration because of its natural tendency to creep untilrestrained by the cylindrical sleeve in which it is stored.

The aforedescribed classical method results in the discharge of aportion of the cheese curd from the mouth of each hoop during thepressing operation. This curd must be trimmed away and salvaged, usuallyat a substantially reduced return. Moreover, the overall horn cheesemaking process requires separately handling each individual horn hoopand cheese.

In most cheese making operations, the major portion of cheese curdprocessed is pressed into blocks. To the extent practical, a cheeseplant uses automated washing equipment to clean its cheese hoops. Theindividual horn hoops are difficult to clean and cannot be handledefficiently in the automated washing equipment relied upon for washingblock cheese hoops. Moreover, the special cheesecloths required for thehorn hoops of the prior art must be separately maintained and cleaned.

Generally, a cheese operation is designed to coordinate its vat capacity(where curd is produced) with its press capacity. The presses aretypically designed to accommodate the number of rectangular block cheesehoops required to press the curd from an integral number of vats. It isnot practical to press blocks and horns simultaneously in a singlepress. As a consequence, when horns are produced the press capacityisnot well coordinated with the associated vat capacity. Because of theaforementioned difficulties, many cheese producers cannot economicallyjustify the production of horns of cheese. Some cheese producers followthe practice of cutting semi-cylindrical shapes from blocks produced inconventional block cheese processes. Mechanically cut horns have enjoyedneither the consumer acceptance nor the price differentialsofconventional horn cheeses. The production of horns by cutting produces alarge percentage of waste. In an effort to reduce this waste, someproducers cut shapes which deviate substantially from the traditionalhorn shape. Moreover, producing horns by cutting techniques is onlypractical for large cheese producers who have a ready use, e.g., cheesespreads and the like, for the scrap remaining from the cuttingoperation. Small and intermediate cheese producers have a substantialneed for an improved method for producing homsof American varietycheeses.

SUMMARY OF THE INVENTION According to the present invention, cheesehorns are pressed in rectangular horn cheese hoops shaped anddimensioned externally approximately the same as conventionalrectangular block cheese hoops. The horn cheese hoops of this inventionmay include parts which are interchangeable with the block cheese hoopsused in the same cheese plant, but ordinarily it is more convenient forthe hoop structures used for the production of horns to be maintainedand stored as complete sets. It is possible to load the rectangular hornhoops of this invention interchangeably with rectangular block hoops ina press to produce simultaneously both horns and blocks, therebyavoiding many of the previously described difficulties andinconveniences. The method and apparatus of the present inventionprovide significant savings on labor, and equipment required to producehorns of cheese. One notable economic advantage provided by thisinvention is that the automated washing equipment conventionallyemployed for washing block hoops is satisfactory for washing therectangular horn cheese hoops of this invention. Horns are produced withmuch less loss of curd during the pressing procedure.

In addition to providing an improved procedure and equipment forproducing horns, the apparatus and method of this invention makes itpractical to press a great variety of specially shaped cheeses withoutthe waste associated with cutting such shapes from block cheeses.According y, many of the shapes heretofore impractical for mostcheesemakers to produce are now economically feasible products.

The apparatus of this invention is used in accordance with proceduresgenerally followed in the production of block cheeses in a rectangularblock cheese hoop, such as the standard 40 pound hoop" conventionallyused in the cheese making industry. According to some embodiments, suchastandard rectangular block hoop is modified by the insertion ofadapters. These adapters may be formed as insertable platens, one ofwhich is positioned in the bottom of the hoop prior to insertion of thecloth and sleeve portions of the conventional hoop and the other ofwhich is inserted in opposition to the first insert atop the cheeseclothafter it is folded over the curd. The top of the rectangular hoop isthen positioned in conventional fashion. Each platen has a pressingsurface comprised of at least one, usually two, concave molds.

An alternative and preferred embodiment of the invention is constructedby mounting the aforementioned adapters (platen members) in rectangularframes having perimeters substantially identical to those of the bottomand top members of the standard rectangular block hoops. These framesare substituted for the bottom and top members to make up a rectangularhorn hoop. The use of the rectangular horn hoops then involves nooperating procedures in addition to those normally followed in the useof conventional rectangular block hoops.

Although the pressing surface of the platen members may include anydesired number and shape of concave molds, the molds of most interestpresently are longitudinal cylindrical sections extending the fulllength of the pressing surface and dimensioned to produce horns ofapproximately the diameter produced in cylindrical horn hoops.

Many aspects of quality control and uniformity of product are enchancedby the improved method provided bythis invention. Thus, contrary to theprocedures of the prior art, the horns of this invention are produced bypressing a predetermined quantity of curd into an approximatelycylindrical shape of predetermined volume by applying pressure across amuch greater surface area than is the case when curd is pressed in acylindrical horn hoop. When the aforementioned platen members are urgedtogether, pressure is applied in opposing directions normal thelongitudinal axis of the pressed horn, rather than parallel to saidlongitudinal axis. It is generally desirable, from the standpoint ofuniformity of quality and shape, to press curd in this fashion ratherthan in accordance with the classical method wherein it is necessary torely to a substantially greater extent upon the flow characteristics ofthe curd to assume the shape of the mold.

Although the platen inserts may include any convenient number of concavemolds, rectangular horn hoops corresponding in dimensions to thestandard 40 pound rectangular block hoops are appropriately dimensionedto receive platens containing two side-byside concave molds. Eachconcave mold is desirably shaped generally as a longitudinal cylindricalsection of no more than semi-cylindrical volume. That is, each mold isshaped as the volume defined by a plane intersecting the cylinderparallel its longitudinal axis. Each such longitudinal section should beno larger than, and preferably somewhat smaller than, a section definedby a plane intersecting the longitudinal axis of the cylinder. It isrecognized that the precise shape of the molds used to produce hornsneed only approximate a cylindrical section. Subsequent aging procedurespermit smoothing of the surface of the pressed horn, due to the naturalflow characteristics of the cheese. Thus, although it is generally mostconvenient to manufacture molds by simply rolling sheet material into acurved plane defining substantially circular arcs in cross section, itis possible for the mold to deviate substantially from a circularcurvature and still produce a pressed shape suitable for hornproduction. The mold may even by polygonal in cross section, providedthe pressed horns do not deviate so substantially from a cylindricalshape as to exceed the ability of the pressed curd to flow into acylindrical shape during the aging process.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings which illustrate whatis presently regarded as the best mode for carrying out the invention,

FIG. 1 is -a pictorial illustration of a plurality of rectangular hoopsloaded in a conventional cheese press;

FIG. 2, an exploded pictorial illustration of one embodiment of thisinvention;

FIGS. 3, 4 and 5, cross sectional views of the embodiment illustrated byFIG. 2, serially illustrating the mode of operation thereof;

FIG. 6, a pictorial illustration of a pair of pressed horns produced inaccordance with this invention;

FIG. 7, a pictorial illustration of a pressed horn being prepared foraging;

FIG. 8, a pictorial exploded illustration, partially cut away, of analternative embodiment of the apparatus of this invention;

FIG. 9, a cross sectional view of the apparatus of FIG. 8 in assembled,fully pressed condition; and

FIG. 10, a fragmentary section in enlarged scale of the region 10-10ofFIG. 9.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS As is illustrated by FIG. 1,the rectangular horn hoops of the present invention may be pressed in aconventional cheese press in the same fashion as the rectangular blockhoops of the prior art. A plurality of rectangular hoops ll of eithertype may be placed in the trough 12 of a conventional cheese press 13.Force is applied to the hoops 11 between a stationary foot 14 and a ram15 (which may be urged toward the foot 14 by any convenient mechanicalmeans) to compress curd contained by the hoops.

In the illustrated instance, the ran 15 is moved by means of a threadedshaft 16journalled to turn in a box 17. Mechanical means (not shown) inthe box 17 may be driven by pneumatic fluid supplied through a line 18.The pressure of the fluid delivered to the box 17 detemiines the degreeof compression or compaction of the cheese curd contained by the hoops11. This pressing procedure has long been conventional for thepreparation of block cheeses. The cylindrical horn hoops of the priorart can be loaded longitudinally on their sides in the trough 12fashion, but with the difficulties and disadvantages discussedhereinbefore.

The rectangular horn hoop of FIG. 2 includes a bottom member 20, covermember 21, sleeve insert 22, and support pins 23 of a conventionalrectangular block cheese hoop. A cheesecloth 24, similar to those usedin connection with a rectangular block hoop, may be located in the sameway, as shown, in the claimed horn hoop.

and pressed in similar Conversion of the rectangular block hoop to theclaimed rectangular horn hoop is accomplished by the insertion of abottom platen member 25 and a top platen member 26. In the illustratedinstance, the bottom platen member 25 includes two side-by-side concavemolds 25a, 25b shaped as longitudinal cylindrical sections somewhatshorter than a semi-cylinder, and the top pressing plate 26 contains twomolds 26a, 26b corresponding in size and shape and oriented to directlyoppose the bottom molds 25a and 25b, respectively. Although variousspecific constructions are permissible, the illustrated platenstructures are generally suitable. Thus, the bottom platen includes asupport means 25c, 25d at each edge to rest on the floor portion 20a ofthe bottom member 20. The platens 25, 26 are dimensioned to slip withinthe sleeve 22, and the sleeve 22 is dimensioned to fit between the edgesof the pressing platens and the top and bottom members as shown.

Referring to FIGS. 3 through 5, the embodiment illustrated by FIG. 2 isused by first positioning the bottom platen member 25 in the bottommember 20 as illustrated. The pins 23 are inserted through the holes 27(FIG. 2), and the sleeve 22 is supported on the pins 23 as shown. Thecheesecloth 24 is then positioned to line the inside surface of thesleeve 22 and the pressing surface comprised ofthe molds 25a, 25b of thebottom platen member 25. The assembled hoop is then ready for theintroduction of curd.

As illustrated by FIG. 4, a predetermined quantity of curd 28 is loadedinto the assembled hoop, the cheesecloth 24 is folded over the top ofthe curd 28, the top platen member is positioned atop the cheesecloth24, the cover member 21 is placed over the sleeve 22 to cover the topplaten member 26, and the pins 23 are withdrawn to permit the sleeve 22to slide down between the bottom member 20 and the bottom platen member25.

A plurality of the hoops, loaded and assembled as illustrated by FIG. 4,may be placed in a press 13 as illustrated by FIG. 1, wherein they arepressed until they compact the curd to the desired extent (FIG. 5). FIG.5 shows how the construction of the illustrated hoop preventsovercompacting the curd. The insert sleeve 22 checks the pressing actionby determining the minimum spacing between the bottom 25 and top 21 ofthe hoop. Even with the hoop in fully pressed condition, the bottom 20and top 21 are slightly spaced as shown at 29. Whether or not the hoopis pressed to its maximum possible extent, the application ofappropriate pressure forms, in the illustrated instance, a pressing 30consisting of two side-by-side, approximately cylindrical pressed horns31 (FIG. 6). The platens 25 and 26 may be deepened so that they contacteach other when pressed, if it is desired to press individualunconnected horns. The hoops are held in the press until the pressingsset, usually several hours or overnight.

The pressed horns 31 are cut apart, individually wrapped in a polyvinylbag 32 (FIG. 7) and inserted in a pasteboard sleeve 33. Thethus-contained horns are stored on end for appropriate periods,generally in excess of about days, for aging. During the aging process,the horns assume a substantially cylindrical shape with the flat regions34 of the pressed horns assuming a circular configuration in conformancewith the internal surface of the sleeve 33.

Although the embodiment previously described is generally suitable andconstitutes a substantial advance in the art, its use requires themanual placement of the adaptive members 25 and 26 in the hoop. Becausethese members can sometimes be forced out of position, requiringreadjustment during the pressing procedure, it is often preferred torely upon the embodiment illustrated by FIGS. 8 through 10. According tothis embodiment, a top pressing platen 40 and a bottom pressing platen41 are mounted within a top frame member 42 and a bottom frame member43, respectively. The sleeve insert 44, cheesecloth (not shown), pins45, and general operating procedure may be identical to thecorresponding elements previously described. In practice, it isdesirable for the sleeve insert 44 to be somewhat shorter than thesleeve insert 22 (FIG. 2) of the conventional rectangular block cheesehoop.

The top frame member 42 comprises a rectangular frame 46 having the sameperimeter as the cover 21 (FIG. 2) of the previously describedembodiment. The top pressing platen 40 is anchored to the frame 46 bymeans of edge members 47 connecting the inside 46a of the frame 46 withthe outside edges 40a of the platen 40. The bottom frame member of thehoop 43 is similarly constructed with the bottom pressing platen 41anchored in a frame 48 by means of the support members 49.

FIG. 9 illustrates the embodiment of FIG. 8 in fully assembled (exceptfor the press cloth and curd) and fully pressed condition. It should benoted that the minimum, fully pressed spacing of the top platen 40 andbottom platen 41, and thus the diameter of the pressed horn, is set bythe height of the sleeve 44 as illustrated by FIG. 10. The size andshape of the pressings can be adjusted to some extent by substitutingsleeves of various sizes.

Reference herein to details of certain preferred embodiments is notintended to limit the scope of the claims which themselves recite thosefeatures regarded as essential to the invention.

I claim:

1. Apparatus for adapting a conventional rectangular block cheese hoop,including a boxlike bottom element, a rectilinear open ended sleeveelement insertable in said bottom element, and a cover element for saidinsert, to produce horn cheeses, comprising:

an adapter element for said bottom element, including a base member forsupport on said bottom element and a pressing surface opposite said basemember including a plurality of concave molds in side-by-siderelationship, each such mold extending the full length of the adapterand being shaped generally as a longitudinal, no more thansemicylindrical section of a cylinder; and

a pressing platen member adapted for insertion into said sleeve oppositesaid adapter element, including a pressing surface with a plurality ofconcave molds corresponding in number to the concave molds of saidadapter element and located to directly oppose said first-named moldswhen the platen member is inserted into said sleeve.

2. A cheese hoop for making horns of cheese, comprising:

prising:

a rectilinear sleeve open at both ends and having rectangular crosssections both normal and parallel said open ends;

a first platen insertable in one end of said sleeve, in-

cluding at least one concave pressing mold shaped approximately as alongitudinal, no more than semi-cylindrical section of a cylinder;

a second platen insertable in the opposite end of said sleeve, includingconcave pressing molds corresponding in number and location andapproximately in shape to those in said first platen so that when thetwo platens are urged toward each other through said sleeve, pairs ofcorresponding molds enclose approximately cylindrical volumes; and

means to prevent said platens from being urged into contact with eachother when said sleeve is loaded with curd and said platens are insertedin its opposite ends.

3. A cheese hoop for making horns of choose, coma rectilinear sleeveopen at both ends and having rectangular cross sections both normal andparallel said open ends;

a first platen insertable in one end of said sleeve, in-

cluding at least one concave pressing mold shaped approximately as alongitudinal, no more than semi-cylindrical section of a cylinder; and

a second platen insertable in the opposite end of said sleeve, includingconcave pressing molds corresponding in number and location andapproximately in shape to those in said first platen so that when thetwo platens are urged toward each other through said sleeve, pairs ofcorresponding molds enclose approximately cylindrical volumes; whereinat least one platen is mounted within a rectangular frame dimensioned toslip concentrically over one end of said sleeve so as to guide saidplaten into said sleeve.

4. A cheese hoop, according to claim 3, wherein each platen has twoconcave pressing molds in side-byside relation so that when'the sleeveis loaded with curd and the platens are urged together the curd ispressed into a connected pair of approximately cylindrical horn cheeses.

UNITED STATES PATENT orrrtr CER'NFICATE M CQRRECTION Patent No.3,700,373 Dated October 24 1972 Infi nt fl Dean A. Fowler It iscertified that error appears in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

Col. 4, line 48, change "ran" to--ram--;

Col. 5, line 8, change "plate" to--p1aten-;

Col. 7, line 19, change "choose" to--cheese-.

Signed and sealed this 22nd day of May 1973.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attesting Officer Commissionerof Patents F ORM PO-1050 (10-69) USCOMM-DC 50376-P69 US, GOVERNMENTPRINTING OFFICE: I969 0-366-334

1. Apparatus for adapting a conventional rectangular block cheese hoop,including a boxlike bottom element, a rectilinear open ended sleeveelement insertable in said bottom element, and a cover element for saidinsert, to produce horn cheeses, comprising: an adapter eleMent for saidbottom element, including a base member for support on said bottomelement and a pressing surface opposite said base member including aplurality of concave molds in side-by-side relationship, each such moldextending the full length of the adapter and being shaped generally as alongitudinal, no more than semi-cylindrical section of a cylinder; and apressing platen member adapted for insertion into said sleeve oppositesaid adapter element, including a pressing surface with a plurality ofconcave molds corresponding in number to the concave molds of saidadapter element and located to directly oppose said first-named moldswhen the platen member is inserted into said sleeve.
 2. A cheese hoopfor making horns of cheese, comprising: a rectilinear sleeve open atboth ends and having rectangular cross sections both normal and parallelsaid open ends; a first platen insertable in one end of said sleeve,including at least one concave pressing mold shaped approximately as alongitudinal, no more than semi-cylindrical section of a cylinder; asecond platen insertable in the opposite end of said sleeve, includingconcave pressing molds corresponding in number and location andapproximately in shape to those in said first platen so that when thetwo platens are urged toward each other through said sleeve, pairs ofcorresponding molds enclose approximately cylindrical volumes; and meansto prevent said platens from being urged into contact with each otherwhen said sleeve is loaded with curd and said platens are inserted inits opposite ends.
 3. A cheese hoop for making horns of choose,comprising: a rectilinear sleeve open at both ends and havingrectangular cross sections both normal and parallel said open ends; afirst platen insertable in one end of said sleeve, including at leastone concave pressing mold shaped approximately as a longitudinal, nomore than semi-cylindrical section of a cylinder; and a second plateninsertable in the opposite end of said sleeve, including concavepressing molds corresponding in number and location and approximately inshape to those in said first platen so that when the two platens areurged toward each other through said sleeve, pairs of correspondingmolds enclose approximately cylindrical volumes; wherein at least oneplaten is mounted within a rectangular frame dimensioned to slipconcentrically over one end of said sleeve so as to guide said plateninto said sleeve.
 4. A cheese hoop, according to claim 3, wherein eachplaten has two concave pressing molds in side-by-side relation so thatwhen the sleeve is loaded with curd and the platens are urged togetherthe curd is pressed into a connected pair of approximately cylindricalhorn cheeses.